U.S. patent application number 12/232546 was filed with the patent office on 2009-05-28 for continuous loading system.
Invention is credited to Peter Guttinger, Tomasz Kardynal, Berger Bemd Pogrzeba, Tony Spadafora.
Application Number | 20090133363 12/232546 |
Document ID | / |
Family ID | 38710534 |
Filed Date | 2009-05-28 |
United States Patent
Application |
20090133363 |
Kind Code |
A1 |
Guttinger; Peter ; et
al. |
May 28, 2009 |
Continuous loading system
Abstract
A system is disclosed for loading a plurality of items into a
plurality of containers. The system may include a plurality of
pucks, each puck adapted to retain an item. A puck delivery
sub-system may include a puck-infeed conveyor to move each of the
pucks along an in-feed conveyor path, and a transition apparatus
operable to facilitate the transition of the pucks to a continuous
puck unloading conveyor. The puck un-loading conveyor may have a
releasable engagement mechanism such that when each of the pucks is
engaged with said puck unloading conveyor, each of said pucks is
fixed in a relative longitudinal position relative to the puck
unloading conveyor. An item transfer apparatus may transfer an item
from each puck when engaged with the puck un-loading conveyor, to a
corresponding container.
Inventors: |
Guttinger; Peter; (Milton,
CA) ; Pogrzeba; Berger Bemd; (Georgetown, CA)
; Spadafora; Tony; (Ancaster, CA) ; Kardynal;
Tomasz; (Mississauga, CA) |
Correspondence
Address: |
SMART & BIGGAR
438 UNIVERSITY AVENUE, SUITE 1500, BOX 111
TORONTO
ON
M5G 2K8
CA
|
Family ID: |
38710534 |
Appl. No.: |
12/232546 |
Filed: |
September 18, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11514998 |
Sep 5, 2006 |
|
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12232546 |
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Current U.S.
Class: |
53/251 |
Current CPC
Class: |
B65G 35/06 20130101;
B65B 35/205 20130101; B65G 2201/0261 20130101; B65B 5/04 20130101;
B65B 43/52 20130101 |
Class at
Publication: |
53/251 |
International
Class: |
B65B 5/00 20060101
B65B005/00 |
Claims
1. A system for loading a plurality of items into a plurality of
containers comprising: (a) a plurality of pucks, each of said pucks
adapted to retain an item; (b) a puck delivery sub-system
comprising a puck-infeed conveyor operable to move each of said
plurality of pucks in series along an in-feed conveyor path portion
while each of said plurality of pucks retains at least one item,
and a transition apparatus operable to facilitate the transition of
said plurality of pucks while retaining said at least one item from
said puck in-feed conveyor to a continuous puck unloading conveyor;
(c) a continuous puck unloading conveyor movable in a longitudinal
direction along a first conveyor path portion, said pucks and said
puck unloading conveyor having a releasable engagement mechanism
operable to facilitate said pucks releasably engaging said puck
unloading conveyor, such that when each of said pucks is engaged
with said puck unloading conveyor, each of said pucks is fixed in a
relative longitudinal position relative to said puck unloading
conveyor; (d) a container conveyor for moving a plurality of
containers in series with fixed longitudinal positions relative to
said container loading conveyor, and said container loading
conveyor moving in a longitudinal direction along a second conveyor
path portion proximate said first path portion of said puck
unloading conveyor; (e) an item transfer apparatus for transferring
said item from each of said plurality of pucks on said puck
unloading conveyor to a corresponding container being moved on said
container conveyor; wherein said item transfer apparatus will
transfer each item retained by pucks once engaged with said puck
unloading conveyor, to a respective container of said container
conveyor, while said puck unloading conveyor is moving along said
first path portion and said container conveyor is moving along said
second path portion, wherein after each item retained by said puck
has been transferred to a carton, said releasable engagement
mechanism is operable to facilitate said pucks being released from
engagement with said puck unloading conveyor.
2. A system as claimed in claim 1 wherein said releasable
engagement mechanism for each puck comprises at least one generally
transversely oriented slot and a generally transversely oriented
rod member receivable in said slot, wherein when a rod member is
received in a slot, the relative longitudinal position of said puck
to said respective rods is fixed.
3. (canceled)
4. A system as claimed in claim 1 wherein said in-feed conveyor
moves said pucks by a frictional force engagement mechanism between
said in-feed conveyor and said pucks.
5. (canceled)
6. A system as claimed in claim 4 wherein said in-feed conveyor has
a conveyor belt with a belt surface and each of said pucks has a
surface, and wherein said frictional force engagement mechanism is
provided between said belt surface and said surface of said
pucks.
7. A system as claimed in claim 1 wherein said container conveyor
is a continuous conveyor that moves in synchronization with the
movement of said continuous puck unloading conveyor.
8. A system as claimed in claim 1 further comprising: (a) a PLC;
and (b) a first drive motor for driving the movement of said
transition apparatus; wherein said PLC is operable to control the
speed of said first drive motor such that the movement of said
pucks can be synchronized with the movement of said puck unloading
conveyor, so that said engagement mechanism between each of said
pucks and said puck unloading conveyor can be engaged.
9. A system as claimed in claim 8 wherein said PLC is operable to
control the movement of said puck unloading conveyor and said PLC
can adjust the movement of said transition apparatus so that said
engagement mechanism between each of said pucks and said puck
unloading conveyor can be engaged.
10. A system as claimed in claim 6 wherein said plurality of pucks
comprises a plurality of groups of pucks, each of said plurality of
pucks having a lead puck, and said transition apparatus is adapted
to control the movement of said lead puck in said plurality of
pucks so that said releasable engagement mechanism between said
lead puck and said puck unloading conveyor can be engaged, and
whereby when said lead puck is engaged with said puck unloading
conveyor, said puck in-feed conveyor will push the remaining pucks
of said group such that said releasable engagement mechanisms
between each of said remaining pucks and said puck unloading
conveyor can also be engaged.
11. A system as claimed in claim 1 wherein said plurality of pucks
comprises at least one group of pucks, each of said at least one
group of pucks having a lead puck, and said transition apparatus is
operable to control the movement of said lead puck in said
plurality of pucks so that said releasable engagement mechanism
between said lead puck and said puck unloading conveyor can be
engaged, and wherein when said lead puck is engaged with said puck
unloading conveyor, said puck in-feed conveyor will push the
remaining pucks of said group such that said releasable engagement
mechanisms between each of said remaining pucks and said puck
unloading conveyor can also be engaged.
12. A system as claimed in claim 11 wherein said at least one group
of pucks comprises a plurality of groups of pucks, each having a
lead puck.
13. A system as claimed in claim 11 wherein said in-feed conveyor
moves at a speed greater than or equal to said puck unloading
conveyor.
14. A system as claimed in claim 13 wherein each of said plurality
of pucks in said group of pucks remains in abutment with adjacent
pucks of said group during the transition from said in-feed
conveyor at least until engagement with said puck unloading
conveyor.
15. A system as claimed in claim 12 further comprising: (a) a PLC
operable to control the movement of said transition apparatus; (b)
a sensor operable to send a signal to said PLC indicative of a
minimum number of pucks being available to form a group and for
delivery to said puck unloading conveyor; wherein upon receipt of
said signal, said PLC is operable to control said transition
apparatus such that the movement of said pucks can be synchronized
with the movement of said puck unloading conveyor, so that said
engagement mechanism between each of said pucks and said puck
unloading conveyor can be engaged.
16. A system as claimed in claim 1 further comprising: (a) a PLC
operable to control the movement of said transition apparatus; (b)
a sensor operable to send a signal to said PLC indicative of a
minimum number of pucks being available for delivery to said puck
unloading conveyor; wherein upon receipt of said signal, said PLC
is operable to control said transition apparatus such that the
movement of said pucks can be synchronized with the movement of
said puck unloading conveyor, and so that said engagement mechanism
between each of said pucks and said puck unloading conveyor can be
engaged.
17-29. (canceled)
30. A system for loading items into a plurality of containers
comprising: (a) a first puck conveyor for moving a plurality of
pucks, each of said pucks retaining an item, along a first path
with a frictional force exerted on said pucks by said first puck
conveyor; (b) a second continuous puck conveyor for moving said
plurality of pucks along a second path in series while each of said
pucks is in a fixed longitudinal connection with said second
continuous conveyor; (c) an apparatus for facilitating the
transition of each of said plurality of pucks from said first puck
conveyor to said second puck conveyor; (d) a container conveyor
moving a plurality of containers in series with fixed longitudinal
positions relative to said container conveyor along a third path;
said second continuous puck conveyor having a path portion of said
second path proximate a path portion of said third path of said
container conveyor; wherein said apparatus will facilitate the
transition of said plurality of pucks from said first puck conveyor
to said second puck conveyor.
31-35. (canceled)
36. A system for loading a plurality of items into a plurality of
containers from a plurality of pucks, each of said pucks adapted to
retain an item, said method comprising: (a) an apparatus operable
to move cach of said plurality of pucks in series along a puck
in-feed conveyor path portion in a longitudinal direction with a
frictional force imparted on each of said pucks; (b) an apparatus
operable to facilitate the transition of said plurality of pucks
from said puck in-feed conveyor to engage a continuous puck
unloading conveyor; (c) an apparatus having continuous movement
which is operable to move said pucks on said continuous puck
unloading conveyor in a longitudinal direction along a first path
portion wherein each of said pucks is fixed in a relative
longitudinal position relative to said puck unloading conveyor; (d)
an apparatus operable to move a plurality of containers in series
with fixed longitudinal position relative to said puck unloading
conveyor, and in a longitudinal direction along a second conveyor
path portion proximate said first path portion of said puck
unloading conveyor; (e) an apparatus for transferring each said
item from each of said plurality of pucks on said puck to a
corresponding container while said apparatus operable to move said
pucks is moving said pucks.
37. A system as claimed in claim 30 wherein each puck comprises:
(a) a body; (b) a receptacle formed in said body for retaining an
item; (c) at least one cam follower extending from said body, said
cam follower having a flange spaced from said body to provide a
slot configured to receive a cam track portion therein.
38-41. (canceled)
42. A system as claimed in claim 30 wherein: said first puck
conveyor comprises a puck-infeed conveyor operable to move each of
said plurality of pucks in series along an in-feed conveyor path
portion of said first path; said second continuous puck conveyor
comprises a continuous puck unloading conveyor; said apparatus for
facilitating the transition comprises a transition apparatus
operable to facilitate the transition of said plurality of pucks
from said puck in-feed conveyor to said continuous puck unloading
conveyor; said pucks and said continuous puck unloading conveyor
having a releasable engagement mechanism operable to facilitate
said pucks releasably engaging said continuous puck unloading
conveyor, such that when each of said pucks is engaged with said
continuous puck unloading conveyor, each of said pucks is fixed in
a relative longitudinal position relative to said continuous puck
unloading conveyor; said system further comprising an item transfer
apparatus for transferring cach said item from each of said
plurality of pucks on said continuous puck unloading conveyor to a
corresponding container being moved on said container conveyor;
wherein said item transfer apparatus will transfer each item
retained by pucks once engaged with said puck unloading conveyor,
to a respective container of said container conveyor, while said
puck unloading conveyor is moving along said first path and said
container conveyor is moving along said longitudinal path, wherein
after each item retained by said puck has been transferred to a
carton, said releasable engagement mechanism is operable to
facilitate said pucks being released from engagement with said puck
unloading conveyor.
Description
RELATED APPLICATIONS
[0001] This is a continuation application of application Ser. No.
11/514,998 filed Sep. 5, 2006, the entire contents of which are
hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the continuous
loading of containers with items.
BACKGROUND OF THE INVENTION
[0003] Systems and methods for loading containers such as for
example cartons, with items, are well known. It is desirable in the
packaging of items to have systems which load such cartons with
items at a high rate. To achieve a relatively high loading rate, it
is preferable to employ systems which load the items in the
containers in continuous movement, rather than systems which bring
both the container and item to a stopped position to carry out the
item loading function.
[0004] Systems are known that employ container conveyors (e.g.
carton conveyors) which carry a series of cartons along a conveyor
path. A bucket conveyor also moves a plurality of items in buckets
along a path that runs parallel and adjacent to the carton
conveyor. Transfer devices, such as barrel loaders, move the items
from the buckets in the bucket conveyor into the cartons held on
the carton conveyor, while both the carton conveyor and the bucket
conveyor are moving in the same general direction. Once the item
transfer has been made, the carton filled with the one or more
items can be taken to another station for further processing.
[0005] One of the drawbacks of such systems is that the buckets on
the bucket conveyor are fixedly attached to the bucket conveyor.
This is required to ensure proper alignment between the bucket
carrying the item and the carton carried on the carton conveyor.
However, since the buckets typically need to be filled while the
bucket is moving, this poses some difficulties. Hesitating bucket
conveyor systems are known such as U.S. Pat. No. 5,226,524 owned by
Langen Packaging Inc. While these do permit the bucket to be loaded
while at a stationary position, these systems require relatively
more complex bucket conveyor design and also the speed at which
items can be unloaded is reduced.
[0006] Accordingly, improved systems and methods for continuously
loading cartons with items are desired.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the invention, there is provided
a system for loading a plurality of items into a plurality of
containers comprising: (a) a plurality of pucks, each of the pucks
adapted to retain an item; (b) a puck delivery system comprising a
puck-infeed conveyor operable to move each of the plurality of
pucks in series along an in-feed conveyor path portion, and a
transition apparatus operable to facilitate the transition of the
plurality of pucks from the puck in-feed conveyor to a continuous
puck unloading conveyor; (c) a continuous puck unloading conveyor
movable in a longitudinal direction along a first conveyor path
portion, the pucks and the puck unloading conveyor having a
releasable engagement mechanism operable to facilitate the pucks
releasably engaging the puck unloading conveyor, such that when
each of the pucks is engaged with the puck unloading conveyor, each
of the pucks is fixed in a relative longitudinal position relative
to the puck unloading conveyor; (d) a container conveyor for moving
a plurality of containers in series with fixed longitudinal
positions relative to the container loading conveyor, and the
container loading conveyor moving in a longitudinal direction along
a second conveyor path portion proximate the first path portion of
the puck unloading conveyor; (e) an item transfer apparatus for
transferring the item from each of the plurality of pucks on the
puck unloading conveyor to a corresponding container being moved on
the container conveyor; wherein the item transfer apparatus will
transfer each item retained by pucks once engaged with the puck
unloading conveyor, to a respective container of the container
conveyor, while the puck unloading conveyor is moving along the
first path portion and the container conveyor is moving along the
second path portion, wherein after each item retained by the puck
has been transferred to a carton, the releasable engagement
mechanism is operable to facilitate the pucks being released from
engagement with the puck unloading conveyor.
[0008] According to another aspect of the invention, there is
provided a system for loading a plurality of items into a plurality
of containers comprising: (a) a plurality of pucks, each of the
pucks adapted to retain an item; (b) a puck delivery system
operable to deliver the plurality of pucks in series to a puck
unloading conveyor; (c) the continuous puck unloading conveyor
movable in a longitudinal direction along a first conveyor path;
(d) the pucks and the puck unloading conveyor having a releasable
engagement mechanism operable to provide the pucks with a
releasable connection to the puck unloading conveyor, such that
when the pucks are connected to the puck unloading conveyor, each
of the plurality of pucks is fixed in a relative longitudinal
position relative to the puck unloading conveyor; (e) a continuous
container loading conveyor for moving a plurality of containers in
series with fixed longitudinal positions relative to the container
loading conveyor, and the container loading conveyor moving in a
longitudinal direction along a second conveyor path having a path
portion proximate a path portion of the path of the puck unloading
conveyor; (f) an item transfer apparatus for transferring each the
item from each of the plurality of pucks on the puck unloading
conveyor to a corresponding container being moved on the container
conveyor; the puck delivery system operable to move the plurality
of pucks in series to the puck unloading conveyor to cause each of
the pucks to connect with the puck unloading conveyor with the
releasable engagement mechanism; wherein when the puck unloading
conveyor moves the pucks along the path portion of the first path
while the pucks are releasably connected to the puck unloading
conveyor, the item transfer apparatus will transfer each item
retained by each the puck to a respective container on the
container conveyor while respective containers are moving along the
path portion of the second conveyor path; wherein after each item
retained by the puck has been transferred to a carton, the
releasable engagement mechanism is operable to facilitate the pucks
being released from engagement with the puck unloading
conveyor.
[0009] According to a further aspect of the invention, there is
provided a system for loading items into a plurality of containers
comprising: (a) a first puck conveyor for moving a plurality of
pucks, each of the pucks retaining an item, along a first
longitudinal path with a frictional force exerted on the pucks in a
first longitudinal path by the conveyor; (b) a second continuous
puck conveyor for moving the plurality of pucks along a second
longitudinal path in series while each of the pucks is in a fixed
longitudinal connection with the second continuous conveyor; (c) an
apparatus for facilitating the transition of each of the plurality
of pucks from the first conveyor to the second conveyor; (d) a
container conveyor moving a plurality of containers in series with
fixed longitudinal positions relative to the container conveyor
along a third longitudinal path; (e) the second continuous conveyor
having a first path portion of the first path proximate a path
portion of the second path of the container conveyor; wherein while
the pucks are moving along the path portion of the second
longitudinal path and the containers are moving along the path
portion of the third longitudinal path, transferring each item
retained by the puck to a respective container.
[0010] According to a still further aspect of the invention, there
is provided a method for loading items into a plurality of
containers comprising: (a) moving a plurality of pucks, each of the
pucks retaining an item, along a first path with a frictional force
exerted on the pucks in a first longitudinal path; (b) facilitating
the transition of the plurality of pucks in series into fixed
longitudinal engagement with a continuous puck moving apparatus;
(c) moving the pucks in series along a second longitudinal path
while in the fixed longitudinal engagement with the continuous puck
moving apparatus; (d) moving a plurality of containers in series
with fixed longitudinal positions relative to a container moving
apparatus, and along a third longitudinal path having a path
portion proximate a path portion of the second longitudinal path;
(e) while the pucks are moving along the path portion of the second
longitudinal path and the containers are moving along the path
portion of the third longitudinal path, transferring each item
retained by the puck to a respective container.
[0011] According to another aspect of the invention, there is
provided a system for loading a plurality of items into a plurality
of containers from a plurality of pucks, each of the pucks adapted
to retain an item, the method comprising: (a) an apparatus operable
to move each of the plurality of pucks in series along a puck
in-feed conveyor path portion in a longitudinal direction with a
frictional force imparted on each of the pucks; (b) an apparatus
operable to facilitate the transition of the plurality of pucks
from the puck in-feed conveyor to engage a continuous puck
unloading conveyor; (c) an apparatus operable to move the pucks on
the continuous puck unloading conveyor in a longitudinal direction
along a first path portion wherein each of the pucks is fixed in a
relative longitudinal position relative to the puck unloading
conveyor; (d) an apparatus for moving a plurality of containers in
series with fixed longitudinal position relative to the puck
unloading conveyor, and in a longitudinal direction along a second
conveyor path portion proximate the first path portion of the puck
unloading conveyor; an apparatus for transferring each the item
from each of the plurality of pucks on the puck to a corresponding
container.
[0012] According to another aspect of the invention, there is
provided a puck for retaining an item comprising: (a) a body; (b) a
receptacle formed in the body for retaining an item; (c) at least
one cam follower extending from the body, the cam follower having a
flange spaced from the body to provide a slot configured to receive
a cam track portion therein.
[0013] Other aspects and features of the present invention will
become apparent to those of ordinary skill in the art upon review
of the following description of specific embodiments of the
invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] In the figures which illustrate by way of example only,
embodiments of the present invention,
[0015] FIG. 1 is a plan view of continuous item loading system,
with some components omitted for clarity.
[0016] FIG. 2 is an enlarged view of the part of the system in FIG.
1, marked as 2 in FIG. 1.
[0017] FIG. 3 is an enlarged, rearward directed, right side
perspective view of the part of the system in FIG. 1, marked as 3
in FIG. 2.
[0018] FIG. 4 is a cross sectional view at 404 in FIG. 2.
[0019] FIGS. 5, 5A and 5B are different perspective views of part
of the system of FIG. 1.
[0020] FIG. 6 is a cross sectional, elevation view at a transverse
plane through line 6 in FIG. 5.
[0021] FIG. 7 is a plan view of the part of the system of FIG.
5.
[0022] FIGS. 8 A-D are sequential, front elevation views of the
part of the system of FIG. 5.
[0023] FIG. 9 is a bottom perspective side view showing in
isolation part of the puck unloading conveyor of the part of the
system of FIG. 5, engaging a plurality of pucks.
[0024] FIG. 10 is a frontward looking front left perspective view
of area 2 in FIG. 2 with the product confining apparatus also
illustrated.
[0025] FIG. 11 is a frontward looking rear left perspective view of
the same area as illustrated in FIG. 10.
[0026] FIG. 12 is a top perspective view in the direction of arrow
12 in FIG. 1.
[0027] FIG. 13 is a top plan view of a puck that may be used in the
system of FIG. 1.
[0028] FIG. 14 is a bottom perspective view of the puck of FIG.
13.
[0029] FIG. 15 is an elevation view of the puck of FIGS. 13 and 14
with a puck free movement conveyor shown in broken outline.
[0030] FIG. 16 is a perspective view of a pusher assembly that is
part of the system of FIG. 1.
[0031] FIG. 17 is an enlarged view of part of the system at 17 in
FIG. 1.
DETAILED DESCRIPTION
[0032] With reference initially to FIGS. 1 and 2, and by way of
overview, a continuous carton loading system 110 is illustrated.
The components of system 110 may include a puck delivery sub-system
111 that may include a puck in-feed conveyor 112, a plurality of
puck clamping devices, 229a, 229b; 230a, 230b; 231a, 231b, and
232a, 232b (generally designated 230). Puck delivery sub-system 111
may also include a puck transition apparatus 174. In addition to
puck delivery sub-system 111, carton loading system 110 may also
include a puck unloading conveyor 116, a carton conveyor 118 and an
item transfer apparatus 120. System 110 may also include a carton
magazine 122, a carton feeder 124 and an item confinement apparatus
(not shown in FIG. 1 or FIG. 2). A Programmable Logic Controller
(PLC 100) may control the overall operation of the components of
system 110.
[0033] Carton loading system 110 may also include a carton conveyor
frame 126 and a puck conveyor frame 170. System 110 may use pucks
132 to carry items 150 (shown only in FIG. 5 for simplicity) to an
item transfer and puck unloading/carton loading station 151 (FIG.
1) where items 150 can be transferred from pucks 132 to cartons 160
(not shown in FIG. 1). The use of pucks 132 may provide significant
benefits and flexibility to the overall packaging system of which
the carton loading system 110 may only be a part. For example, the
use of pucks 132 may provide for greater flexibility in the loading
of items 150 to be carried to the carton loading station 151.
[0034] As shown in FIGS. 13, 14 and 15, pucks 132 may be configured
in many different ways such that they may be moved as a result of a
frictional force imparted upon the puck by a moving surface of a
moving apparatus contacting a surface of the puck. By way of
example only, pucks 132 may each have a base 144 to which is
mounted or integrally connected, an item receptacle portion
generally designated 139. Item receptacle 139 may have a base 138
and two transversely oriented side walls 136a, 136b, and may thus
hold therein one or more items 150 which are to be loaded into a
carton 117 (FIG. 2). Pucks 132 may be made from any one or more
suitable materials. For example, the receptacle portion 139 and
base 144 may be integrally formed of a suitable hard plastic or any
other suitable material.
[0035] Depending from a downward facing surface 138b of receptacle
portion 139 may be mounted transversely opposed cam followers 154a,
154b. Cam followers 154a, 154b may be configured to engage the edge
of adjacent cam plates as is described hereinafter. Cam followers
154a, 154b may each have lower flanges which assist in maintaining
the stability of the pucks 132 as they move through the system,
particularly during the item loading process at station 151, as
described hereinafter.
[0036] With reference to both FIGS. 1 and 15, puck in-feed conveyor
112 of puck delivery sub-system 111 may comprise a conveyor having
a belt 130 which may be driven with intermittent or continuous
movement, and opposed side rails 134a, 134b. Pucks 132 may rest
directly upon a belt 130 and be generally carried around the path
of puck in-feed conveyor 112 by belt 130 while being guided by
rails 134a, 134b, engaging side walls 140a, 140b of puck base
portion 144. Belt 130 can be formed as a flexible conveyor belt,
which enables belt 130 to readily negotiate corners or curves in
the path of in-feed conveyor 112.
[0037] Puck in-feed conveyor 112 can generally be formed of an
aluminum-extruded beam construction, with low friction slide rails
guiding a plastic multi-flexing belt 130. Flexible link conveyor
systems suitable for deployment as conveyor system 112 include the
Flex Link conveyors made by SKF or FlexLink AB. Belt 130 may be
driven by a drive motor that may be controlled by PLC 100. Belt 130
may also be driven continuously by a drive motor that can also be
provided as part of the conveyor system made by a supplier such as
SKF or FlexLink AB
[0038] Belt 130 may have an upper surface that co-operates with
lower surface 138b of base portions 144 of pucks 132, to provide
sufficient frictional engagement between belt 130 and base 144 of
the puck members 132 to move the pucks 132 along the conveyor path
when the pucks are not obstructed. Pucks 132 in series on belt 130
can, however, vary their longitudinal position on the path in
relation to each other when a force is exerted on a puck in the
opposite direction to the movement of belt 130 that overrides the
frictional engagement force between the puck(s) and the belt. In
such circumstances, belt 130 may slide relative to lower surface
138b of pucks 132.
[0039] Belt 130 may be supported and guided in part by horizontally
oriented idler sprockets, which in the illustrated embodiment may
be disposed at curved portion 112a (FIG. 1) to assist in providing
a partially curved conveyor path for in-feed conveyor 112. The
idler sprockets may have an upward facing surface, which
frictionally engages the underside of belt 130 and so rotate with
the movement of belt 130. Belt 130 may have a cross section shaped
like a horizontal H so idler sprockets fit in between the top
horizontal and the bottom horizontal portions and can guide belt
130 from both above and below.
[0040] Puck in-feed conveyor 112 may also be part of a larger puck
loading system which has located upstream one or more item loading
stations (not shown) where items 150 can be loaded into the pucks
132 using known types of loading apparatus. Item loaders could be
provided to load any kind of items into pucks such as by way of
example only, rolls of plastic bags. Pucks 132 may be easily
delivered to in-feed conveyor 112 from multiple in-feed channels
thereby providing greater flexibility in feeding pucks 132 onto
puck in-feed conveyor 112.
[0041] With reference now to FIGS. 1, 5, 6, 7 and 8a, the
components of system 110 at puck transition station 152 are shown
in detail, including puck transition apparatus 174. In general,
puck in-feed conveyor 112 delivers pucks 132 on belt 130 to
transition station 152. Transition station 152 may perform the
function of accumulating a plurality of pucks 132 into a group
generally designated 155. The group may have a pre-determined
minimum number, that once reached, will result in the commencement
of the transfer of pucks from in-feed conveyor 112 to puck
unloading conveyor 116. Apparatus 174 may then facilitate the
transition of the lead puck in the group onto puck unloading
conveyor 116 whereby the entire group may be transitioned into
engagement with the puck un-loading conveyor 116. By providing
appropriate timing of the lead puck 132 of group 155, and if for
the remaining pucks in the group of pucks 132, contact is
maintained with adjacent pucks, at least until each puck engages
with the puck unloading conveyor 116, all pucks in the group will
also be appropriately timed for engagement with puck unloading
conveyor 116 and make the transition from in-feed conveyor 112. The
number of pucks 132 in any specific group 155 may be indefinite,
and the number of pucks in different groups may vary. Pucks 132 may
continue to accumulate as part of the group 155 and be continually
delivered to puck unloading conveyor 116, until a discontinuity or
interruption in supply occurs such that a gap is formed between at
least one pair of adjacent pucks. An illustrated group in FIG. 8a
comprises six pucks, all of which become synchronized with puck
unloading conveyor 116.
[0042] If there is an un-interrupted supply of pucks 132 provided
by in-feed conveyor 112, so that there is no gap between any
adjacent pucks 132 being moved through transition station 152, then
pucks 132 may continue to be automatically pushed into synchronized
engagement by the movement of in-feed conveyor 112 (which moves at
least as fast, and preferably faster, than conveyor 116) and the
length of the group of pucks will continue to accumulate. If
however, a gap between a pair of adjacent pucks 132 is detected
prior to delivery to the puck unloading conveyor 116, transition
apparatus 174 will be activated again to terminate the continuation
in supply of pucks to the first group. Transition apparatus 174
will then be located so as to identify a new lead puck 132 and the
next group of pucks will start to be accumulated until again a
pre-determined minimum number of pucks is accumulated.
[0043] As illustrated for example in FIGS. 5 and 5a, longitudinally
aligned with the end of belt 130 may be a pair of spaced,
longitudinally oriented rail members 444a, 444b. Rail members 444a,
444b may assist in guiding pucks 132 in making the transition from
in-feed conveyor 112 to puck unloading conveyor 116. Rails 444a,
444b may be made of any suitable material including a hard plastic,
a metal such as steel or aluminum, or any other suitable material.
The upper surfaces of rails 444a, 444b, may be configure to engage
the lower surfaces 138b of the receptacle base 138 and thus may
support pucks 132 as they pass from belt 130 to be engaged by cross
bars or rods 145 of puck unloading conveyor 116. Rails 444a, 444b
may also be part of a system overload feature. For example, the
rails 444a, 444b may be mounted for upward pivoting movement about
a pivot location with pivoting movement being effected by, for
example, pneumatic cylinders with interconnected pivot arms (not
shown). In the event that a puck 132 does not properly engage with
rods 145 in the manner shown, for example in FIG. 9, an optical
sensor located proximate the rod engagement location may detect the
same and send a signal to PLC 100. PLC 100 can then, in addition to
shutting down conveyors 112 and 116 (which may take a short amount
of time before they stop moving), also cause rails 444a, 444b to
elevate, thus reducing the risk of pucks damaging one or more other
parts of the system 110.
[0044] Puck transition apparatus 174 may be mounted to part of the
frame generally designated 170. Frame 170 may have vertical members
170a, one or more transverse members 170b and one or more
longitudinal members 170c in the vicinity of puck transition
apparatus 174. Mounted and supported by frame 170 is a
longitudinally oriented track 172. Puck transition apparatus 174
may have a slide plate 176 that may slide backwards and forwards on
track 172 in a longitudinal direction. Depending vertically
downward toward from a rearward end of slide plate 176 may be a
plate 178. Mounted transversely and horizontally to the end of
plate 178 may be a support block 190. At each end of support block
190 may be a housing 194, each housing having a transversely
oriented aperture. Each aperture supports an end of a transversely
mounted shaft 192, allowing rotation of the shaft about its
longitudinal axis. The aperture in each housings 194 may be
provided with a bushing or bearing to permit shaft 192 to easily
rotate about its longitudinal shaft axis.
[0045] Depending from, and fixed for rotation with, shaft 192 is a
holding member 188 that may be shaped like a paddle. Holding member
188 may rotate clockwise and anti-clockwise between a generally
downward 6 o'clock position shown for example in FIG. 8a, and a "9
o'clock" position shown for example in FIG. 8c.
[0046] Shaft 192 may have attached proximate one end thereof, a
crank arm 184 that may be interconnected proximate an end of a
piston arm 184 of a double acting pneumatic cylinder 180. The rear
end of cylinder 180 may be attached to the sliding plate 176.
Extension and retraction of piston arm 184 may cause crank arm 184
to rotate, thus rotating holding member 188 between the positions
shown in FIGS. 8a and 8c. The operation of pneumatic cylinder 180
may be controlled by PLC 100 in conjunction with electronic valves.
Thus, holding member 188 can be used to engage the leading wall
136b of item receptacle 136 of a leading puck 132 of a group of
pucks located at transition station 152.
[0047] A puck rear wall engagement member 187 is affixed to the end
of reciprocating arms 186a-c (FIG. 6b). One or more of arms 186a-c
may be a piston arm of a respective double acting pneumatic
cylinder housed in a mounting block 198. Arms 186a-c may be
reciprocally moved axially in and out of block 198. Mounting block
198 may be mounted to sliding plate 176. Arms 196 reciprocate to
move the engagement member 187 between the extended position shown
in FIG. 8a and the retracted position shown in FIG. 8c. The
operation of pneumatic double acting cylinders in block 198 may
also be controlled by PLC 100 in conjunction with electronic
valves. Thus, rear wall engagement member 187 can be used to engage
the trailing wall 136a of item receptacle 139 of a leading puck 132
of a group of pucks located at transition station 152.
[0048] Compressed air can be supplied to the pneumatic cylinders
from a source by piping (not shown) that is housed inside an
extendible and retractable hose device 218 (known as a flexible
wire/hose track device). Device 218 will move with transition
apparatus 174 thus continuing to supply electrical power/signals
and compressed air to transition apparatus 174.
[0049] Puck transition apparatus 174 can thus move along track 172
and in doing so move the leading puck 132 of a group of pucks with
it, to move the leading puck over the rails 444a, 444b in such a
manner as to engage with cross rods 145 of puck unloading conveyor
116.
[0050] A drive apparatus 200 is provided for moving puck transition
apparatus 174 in reciprocating movement forward and backward along
track 172. Drive apparatus 200 may include a vertically oriented
endless drive belt 202 supported at one end by an idler 204 and at
the other end by a drive wheel 206. Drive wheel 206 may be powered
by a drive shaft of a servo-motor 208 which can rotate drive wheel
206 in both directions. Idler 204, drive wheel 206 and motor 208
may be supported and mounted on frame 170. Thus rotating drive
wheel 206 will move belt 202 in a direction corresponding to the
direction of rotation of drive wheel 206.
[0051] A resolver/encoder (not shown) may be associated with the
drive shaft of motor 208. In this way, rotation of the drive shaft
of motor 208 can be associated with a location on belt 202. In
particular, since the puck transition apparatus may be directly
interconnected to belt 202, the longitudinal position of belt 202
can be provided to PLC 100 by way of the signals provided by the
resolver associated with motor 208. However, a separate
resolver/encoder associated with drive motor 208 may not be
necessary. Once puck transition apparatus 174 is properly
positioned, the operation of drive motor 208 could be tied directly
with a resolver/encoder associated with the drive shaft 241 and/or
drive motor of puck un-loading conveyor 116. Thus, the drive motor
208 may be controlled by PLC 100 so that transition apparatus 174
is driven until a lead puck is synchronized with a pair of rods 145
of puck unloading conveyor 116.
[0052] Belt 202 is interconnected to puck transition apparatus 174
by a clamp 213 having vertically oriented and interconnected clamp
arms 212a, 212. Clamp arms 212a, 212b are positioned on opposite
sides of belt 202 and sandwich belt 202 between the arms. Clamp 213
may be adjustable so that the longitudinal position of the clamp on
belt 130 may varied. Mounted to the bottom of clamp arm 212b is a
transversely extending plate 210 which is interconnected to a rear
surface of sliding plate 176. When belt 202 moves longitudinally,
side plate 176 may be driven along track 172, in either
direction.
[0053] Positioned at upstream locations in and from transition
station 152 are one or more spaced puck clamping devices designated
230. In the illustrations are shown several clamping or puck
restraining devices 229a, 229b; 230a, 230b; 231a, 231b, and 232a,
232b. As shown in FIG. 7, devices 230 have arms 433a, 433b which
can engage on opposed surfaces 144e, 144f of pucks 132 (see FIGS.
13 and 14) and so provide forces to oppose the forces created by
the pucks 132 as they attempt to move downstream. It will be
appreciated that when puck transition apparatus 174 is in a puck
blocking/restraining position such as is shown in FIG. 8a, none of
pucks 132 in group 155 can move longitudinally downstream on belt
130. The result is that the belt slides under the lower surface of
base 144 of each puck. However, this relative movement creates an
additional force on the belt 130 in the upstream direction. As more
pucks accumulate at station 152, the total friction force continues
to accumulate, with each additional puck 132 adding to the total
load. To assist transition apparatus 174 in resisting this load
imparted by all the accumulated pucks 132, one or more of the
plurality of puck clamping devices, 229a, 229b; 230a, 230b; 231a,
231b, and 232a, 232b can be activated to provide resistance forces
in an upstream direction at one or more suitable locations. The
precise number and location of devices like puck clamping devices,
229a, 229b; 230a, 230b; 231a, 231b, and 232a, 232b can be selected
depending upon the particular application. However, providing one
or more devices 230 upstream of transition apparatus may ensure
that transition apparatus 174 does not, on its own, have to resist
the load of all the pucks 132 as they accumulate and are held
stationary.
[0054] With reference to FIG. 1, an optical sensor 233 can be
provided just upstream of any one or more of the puck clamping
devices 230, and may detect the presence of a puck 132 for a
constant pre-determined period of time on belt 130 proximate that
location. This will mean that a pre-determined minimum number of
pucks 132 have accumulated and are ready for delivery by the
delivery sub-system, to puck unloading conveyor 116. PLC 100, upon
receiving a signal from such a sensor, may send signals causing all
activated clamping devices 230 to release the pucks they are
respectively clamping, and thus triggering pucks that have
accumulated in a group 155 to start to move downstream. This can
occur at approximately the same time as transition apparatus 174
starts to move the lead puck to synchronize the lead puck with puck
unloading conveyor 116.
[0055] Next, as illustrated in FIG. 1, the features of puck
unloading conveyor 116 will be described. Puck unloading conveyor
116 receives pucks 132 at transition station 152 that are supplied
by puck in-feed conveyor 112, and which may make the transition
with the assistance of puck transition apparatus 174. Pucks 132
become positively engaged in a fixed longitudinal position on puck
conveyor 116 which takes the pucks 132 to item transfer and puck
unloading station 151 where pucks 132 are unloaded of items 150 and
the items are loaded into cartons 117 being carried by carton
conveyor 118. The engagement mechanism that fixes the longitudinal
position of the pucks 132 relative to conveyor 116 is not simply a
frictional engagement. Any force that is applied to the pucks 132
in a longitudinal direction may be resisted by the contact between
the surfaces of the walls of puck slots 141a, 141b and the surfaces
of rods 145. While the mating surfaces of slots 141a, 141b and rods
145 are curved, other possibilities are possible, so long as the
force interaction in a longitudinal direction between the surfaces
is not simply a frictional resistance force. If the resistance to
longitudinal movement of the puck relative to the conveyor 116 were
only due to a frictional engagement, there would not be a
sufficient degree of assurance that the puck would remain in a
suitable longitudinal position on conveyor 116 to provide for
proper loading of the cartons.
[0056] With particular reference now to FIGS. 2, 5, 9 and 12,
conveyor 116 may comprise a pair of endless chains 240a, 240b are
supported between idlers 242a, 242b, respectively and drive
sprockets 244a, 244b. Chains 240a, 240b may be guided and supported
along a chain path by guide rails 246 (FIG. 3). Drive sprockets
244a, 244b may be driven by a common drive shaft 241 (FIG. 2) which
is rotated by one or more motors (not shown) which may for example
also be AC motors, DC motors or servo motors. Accordingly, drive
sprockets 244a, 244b may rotate together to move chains 240a, 240b
together in the direction of the arrows shown in the drawings.
[0057] The drive sprockets 244a, 244b may drive the chains 240a,
240b at a speed that is less than the speed of belt 130. This will
ensure that a back pressure can be provided to ensure that pucks
132 in a group 155 will remain in contact with each other as they
transition from puck in-feed conveyor 112 to puck unloading
conveyor 116. The rotation of drive sprockets 244a, 244b driven by
the servo-motors, can be controlled by PLC 100.
[0058] Suspended between chains 240a, 240b, at a pre-determined
pitch X3 (FIG. 9) are transverse rods 145 which are configured to
engage slots 141a, 141b on the lower surface of base 144 of each
puck 132. As shown in FIG. 9 (where only one side with idler 242a
and chain 240a is shown for illustration purposes), the distances
X1 and X2 of pucks 132 may be chosen so that the rods 145 will
successively and properly engage slots 141a, 141b of successive
pucks 132a, 132b, 132c. It will also be appreciated that only some
of rods 145 are shown for simplicity in FIG. 9.
[0059] It should be noted that the relative position of rods 145
can be known to PLC 100 by use of a resolver associated with drive
shaft 241 of conveyor 116. Signals sent by a resolver associated
with the rotational position of drive shaft 241 and/or drive
sprockets 244a, 244b, to PLC 100, will enable PLC 100 to determine
where rods 145 carried by chains 240a, 24b are located at any given
time.
[0060] PLC 100 may operate so that motor 208 of belt 202 may be a
slave to the drive motor of conveyor 116. Thus, PLC 100 may adjust
the speed of motor 208 such that the puck transition apparatus 174
can be moved in a manner so that the speed and position of lead
puck 132 in the group 155 will be synchronized with the rods 145
carried by conveyor 116 to allow the lead puck to mesh with first
and second rods 145.
[0061] This may be possible because the positions of at least rods
145 (and possibly belt 202) may be known to PLC 100 by use of the
one or more resolvers described above. Thus, the relative positions
of puck transition apparatus 174 (and thus of a lead puck of a
group 155), and of rods 145 on conveyor 116, may be known to PLC
100. PLC 100 can then adjust the speed of the servo-motor 208
driving belt 202 to achieve synchronization of the lead puck 132 in
the group.
[0062] With reference to FIG. 12, the discharge end 250 of conveyor
116 is illustrated and may include a discharge ramp 252 oriented
generally downwards. Ramp 252 may have rails 254a, 254b, and may
also be provided with rollers 256 which may engage the underneath
surface 138b of pucks 132 to enable pucks to discharge from
conveyor 115 onto a puck out-feed conveyor 262. Out-feed conveyor
262 may thus carry discharged pucks 132 away for further processing
which may include being re-filled with items 150 and being cycled
back to puck in-feed conveyor 112. Out-feed conveyor 262 may be
constructed in a manner similar to in-feed conveyor 112 and have a
belt 260 driven by drive sprockets interconnected to a drive motor.
Out-feed conveyor may also have guide rails 264a, 264b like rails
134a, 134b referenced above. Out-feed conveyor 262 may also be
controlled by PLC 260.
[0063] While ramp 252 with rails 254a, 254b and rollers 256, uses
gravity and the forward momentum of the pucks 132, to assist with
discharging the pucks from conveyor 116, any other suitable
discharge apparatus or mechanism can be employed. For example, an
intermediate bridge conveyor or a transition apparatus that may be
constructed similar to transition apparatus 174 that will engage
each puck and push it over a pair of rails onto belt 260.
[0064] With particular reference to FIGS. 2, 3 and 4, mounted on
frame 170, above conveyor guide rails 246 on conveyor 116, are cam
plates 270a and 270b. The cam plates 270a, 270b are configured to
co-operate with cam followers 154a, 154b respectively of pucks 132.
As will be evident from FIG. 4, cam plates 27a, 270b engage the cam
followers 154a, 154b above and in the slot provided between flanges
156a, 156b respectively and corresponding lower surfaces 138b of
the pucks. Thus flanges 156a, 156b may assist in maintaining the
pucks 132 in firm engagement with the rods 145 of conveyor 116.
This may be of particular importance during the item unloading
process, to ensure that the pucks 132 remain in a proper unloading
position relative to cartons 117.
[0065] As can be appreciated from FIGS. 2 and 3, as pucks 132 are
driven by rods 145 along the path of conveyor 116, the cam plates
270a, 270b will engage the cam followers 154a, 154b respectively to
slide the pucks 132 transversely on rods 145. At item transfer
station 15, pucks 132 can be brought transversely toward carton
conveyor 118 so that pucks 132 can be positioned transversely
adjacent to and longitudinally aligned with cartons 117 being
carried on the carton conveyor 116 to permit unloading of items 150
from pucks 132 into cartons 117. As shown, cam plates 270a, 270b
may also be configured to slide the pucks 132 away from the carton
conveyor 118 once the item unloading from the pucks 132 has been
completed.
[0066] With reference now to FIGS. 2, 3, 4 and 10, the item
transfer apparatus generally designated 120 facilitates the
transfer of items 150 from pucks 132 into the cartons 117. Item
transfer apparatus 120 may include a transverse item pushing
apparatus 280 and a vertical confining apparatus 282 (for
simplicity the latter is not shown in FIGS. 2, 3 and 4).
[0067] With reference also to FIG. 16, pushing apparatus 280 may
include a plurality of pusher assemblies 284. Pusher assemblies 284
may include a pusher bar 300 mounted with a slide block 301 to, and
able to slide backwards and forwards on, slide bars 302.
[0068] Pusher bars 300 may have extending upwards a cam follower
304 for engaging a cam track 312. Pusher assemblies 284 also
include mounting blocks 306a, 306b which enable the pusher
assemblies to be mounted and supported on a pair of endless
conveyor chains (not shown) which rotate about idler sprockets
296a, 296b and drive sprockets 294a, 294b. Drive sprockets 294a,
294b may be mounted on a drive shaft 298 which may be an extension
of drive shaft 241 of the puck unloading conveyor 116. If drive
sprockets 294a, 294b and idler sprockets 296a, 296b of the pusher
assembly conveyor 286 are the same diameter as the drive sprockets
244a, 244b and idler sprockets 242a. 244b, of puck unloading
conveyor 116, pusher assemblies 284 may move at the same speed as
the pucks 132. By ensuring that the two conveyors 116 and 286 are
synchronized in both position and speed, the pusher assemblies 284
can be positioned so that the pusher bars 300 may move the pusher
heads 312 into the item receptacles 139 of the pucks 132 to
dislodge one or more items 150 held therein.
[0069] PLC 100 can thus control the movement of both the puck
unloading conveyor 116 and the pusher conveyor 286 by controlling
the operation of the common drive motor(s).
[0070] As pusher assemblies 284 move around the path of pusher
conveyor 286, cam followers 304 will, during normal operation,
enter an entrance 312a of pusher cam track 312 (path A). This will
move the cam follower 304 of each pusher assembly such that the
pusher arm 300 will move transversely such that the pusher head 312
of each pusher assembly 284 will enter a respective receptacle 139
of a puck 132. This may push an item or items 150 out of the
receptacle 139 and into a carton carried in a slot 121 (see FIG.
11) on carton conveyor 120.
[0071] With reference now to FIG. 17, cam track 312 is defined by
an outer rail 311 and an inner rail 313. A brace member 325 may be
provided to support outer rail 311. The end of a piston arm 314 of
a double acting cylinder 315 is affixed to an end of a rod 321. Rod
321 has its opposite end interconnected to a pivot bracket. Rail
313 is connected to inner rail 313. The extension and retraction of
piston arm 314 will cause rail 313 to move inwards or outwards. The
position of rail 313 shown in FIGS. 1 and 17 is the most outwardly
rotational position of the rail. Rail 313 may be rotated inwards
when a problem is detected in system 110 and it is not desired that
cam followers 304 mounted on one or more pusher bars 300 should
follow the cam track path A to cause the pusher arm to be
maintained in the extended positions imposed by path A extended.
This may be part of the system overload feature. If a problem is
detected by a sensor, PLC can cause cylinder 315 to be retracted
thus releasing any outward transverse load on any pusher arms 300
travelling in track 312 that might arise.
[0072] Another system feature that can deal with problems in the
carton conveyor may include an optical sensor appropriately
positioned relative to carton conveyor 118. This optical sensor may
detect when a carton 117 is not in the correct position in a slot
121 on carton conveyor 116 and thus no carton is ready to receive
an item 150. In such circumstance, the sensor sends a signal to PLC
100, which in turn causes a switch 399 (FIG. 17) to operate to
direct the cam follower 304 on the corresponding pusher bar 300 to
be directed instead down path B. The result is that for that
particular pusher bar 300 that would engage a puck 132 aligned with
a carton slot 121 that does not have a carton 117, the cam follower
304 does not follow the cam track 312 on path A, but instead
follows the track of path B, and so an item 150 is not discharged
from the appropriate puck 132 into the unfilled carton slot 121. A
reserve tank of compressed air 319 may be provided to supply
primary or reserve compressed air, to activate cylinder 315 and/or
switch 399 with a very quick response time (which may be necessary
in the event that a fault is identified in the operation of the
system as just described).
[0073] Vertical confining apparatus 282 may be constructed in a
manner that is quite similar to item pushing apparatus 280, but
with the conveyor being oriented generally about vertical axes as
opposed to horizontal axes. Apparatus 282 may comprise a plurality
of confining members 340 that are part of confining member conveyor
360. Conveyor 360 includes conveyor chains 352a, 352b that are
supported and guided along a conveyor path. Chains 352a, 352b are
driven about idler sprockets 354a, 354b to rotate the confining
members 340 around the conveyor path. Confining members 340 may
include arms 342 which have mounted thereto at a distal end, a
confining block 345. Confining block 345 is configured to be
positioned above and may slide into the top of a receptacle 139
between receptacle walls 136a, 136b.
[0074] Arms 342 have rollers 343 that may engage rails or slots in
slider bars 346, thus allowing arms 342 to move reciprocally up and
down on slider bars 346. Arms 342 may also have depending
therefrom, a cam follower 348 which can be received in a cam track
350 on a side 341 of conveyor 360. When cam followers 348 follow
cam track 350, arms 342 move so as to confine items held in
receptacles 139 of pucks 132 so that items 150 may not be displaced
vertically upwards out of the receptacle but are guided into
cartons 117 when pusher bars 300 move transversely through
receptacles 139.
[0075] Drive sprockets 356a, 356b, may be mounted on a common drive
shaft (not shown) and driven by suitable motors at the same speed
as pusher conveyor 286 and puck unloading conveyor 116.
[0076] With reference to FIG. 1, another component of system 110 is
carton conveyor 118 that moves cartons 117 along a path at item
transfer station 151 that is adjacent to pucks 132 carried on puck
unloading conveyor 116. Cartons 117 on carton conveyor 118 move in
the same longitudinal direction as pucks 132 at station 151. A
carton magazine 122 may be provided upstream of the carton conveyor
118 to store a plurality of cartons. A carton feeder 124 is
operable to remove cartons 117 from magazine 122 and place them
between flights 119a, 119b mounted on conveyer chains 113a, 113b
respectively into slots designated 121. Examples of carton feeding
systems that might be employed are disclosed in U.S. Pat. Nos.
7,081,079 and 5,997,458 owned by Langen Packaging Inc., the entire
contents of which are hereby incorporated herein by reference.
[0077] The position of flights 119a, 119b and thus the position of
carton 117 held in slots 121, are such that the opening to each
carton will be aligned with an adjacent opening of a receptacle 139
of pucks 132 when the pucks and the cartons move longitudinally
through the item transfer station 151.
[0078] In operation, PLC 100 may in starting up system 110,
activate the drive motors to start the movement of carton conveyor
118, puck unloading conveyor 116 along with pusher conveyor 286,
and confining member conveyor 360. PLC 100 may also start up
out-feed conveyor 262. These components may then be in a normal
operating state, where the position of rods 145 on puck unloading
conveyor, flights 119a, 119b on carton conveyor 118, pusher
assemblies 284 on pusher conveyor 286 and confining members 340 on
confining conveyor 360 are all synchronized so that: (a) pucks 132
may be aligned with cartons 117 held in slots 121; (b) pusher bars
300 may be received into receptacles 139 of adjacent pucks 132; and
(c) confining blocks 345 may be suitably positioned above or in an
upper portion of receptacle 139 so as to vertically confine items
150 held in receptacles 139 during unloading of the items 150 from
pucks 132.
[0079] Thus, with system 110 in an operational mode as just
described, pucks 132 carried on puck in-feed conveyor 112 and
already loaded with one or more items 150 may be fed to transition
station 152. Pucks may be accumulated upstream from station 152 and
clamping devices 230 may assist transition apparatus 174 in holding
up the downstream pressure that accumulates as more and more pucks
132 arrive. The lead puck in the group may be held at a stationary
"holding" position as shown in FIG. 8a, by paddle 188 and rear
panel engagement member 187. Once a sensor such as a sensor 233
(FIG. 1) detects that the minimum number of pucks have accumulated
to form a group for delivery, PLC 100 can cause the lead puck of
the group 155 to be moved by transition apparatus 174 and clamping
devices 230 to release upstream pucks.
[0080] In response to PLC 100 receiving information or signal
indicating that the minimum desired number of pucks 132 are at
station 152, PLC 100 may then operate servo-drive motor 208. PLC
100 may operate such that the motor 208 of belt 202 will be a slave
to the servo-drive motor of conveyor 116. Thus, PLC 100 may move
the lead puck 132 in group 155 and in doing so adjust the speed of
motor 208. Accordingly, paddle 184 and engaging member 187, which
are interconnected to belt 202, can be moved in such as manner that
the speed and position of lead puck 132 in the group of pucks will
become synchronized with the rods 145 carried by conveyor 116.
Therefore, as the transition apparatus 174 moves from the position
shown in FIG. 8a to the position shown in FIG. 8b, the lead puck
will pass over rails 444a, 444b and then the front slot 141b of the
lead puck will engage a rod 145 followed by rear slot 141a engaging
the next rod 145. It may take about 11/2 puck lengths for the lead
puck to be synchronized with the position of a rod 145 carried on
conveyor 116. Rails 444a, 444b, permit the lead pucks longitudinal
position to be synchronized with first and second rods 145 prior to
actually the slots of the lead puck attempting to engage the rods
145.
[0081] As belt 130 may be continuing to move at a speed at least as
fast, if not faster, than the speed of conveyor 116, the pucks 132
following behind the lead puck, may continue to be pushed into
abutment with each other forming a continuous group 155 of pucks
132. The transition apparatus 174 may however, control or assist in
controlling the speed and position of all the pucks 132 in the
group for about another 2 puck lengths until the lead puck reaches
the position shown in FIG. 8c. At this position at least the first
two pucks in the group, and possibly 21/2 to 3 lead pucks, may be
in a position to and be engaged by rods 145 carried by conveyor
116. At this position, PLC 100 can send one of more signals to
cause the pneumatic cylinders associated with paddle 188 and
engagement member 187 to be activated. This may cause paddle 188
and rear engagement member 187 to move to the release positions
shown in FIG. 8c. Even though a significant downstream force may be
exerted on the pucks that have engaged with rods 145 from upstream
pucks being pushed by belt 130, the cam followers 154a, 154b with
flanges 156a, 156b respectively will hold those lead pucks firmly
on the rods 145. This may also ensure that pucks 132 that are just
upstream will also remain stable during the transition process.
[0082] Once the first two or three pucks in group 155 are engaged
with rods 145 of conveyor 116, the remaining pucks 132 of the group
155 will be driven by belt 130 into engagement with corresponding
additional rods 145 on the conveyor. The result may be that all
pucks 132 in group 155 will be transferred from in-feed conveyor
112 to the puck unloading conveyor 116. Pucks 132 may thereafter
continue to accumulate indefinitely so long as pucks 132 are
continuing to be supplied by in-feed puck conveyor 112 without gaps
between adjacent pucks.
[0083] After the transition apparatus 174 has released the lead
puck 132 in the group of pucks as shown in FIG. 8c, PLC 100 will
cause the transition apparatus 174 to move quickly backwards along
track 172 to a hold position (with paddle 188 still pivoted at the
horizontal position and member 187 retracted). So long as the
optical sensor in the vicinity of station 152 does not detect any
gaps between adjacent pucks 132 that have not yet reached rails
444a, 444b (or at least not been engaged by puck unloading conveyor
116, pucks 132 will be continued to be supplied and pushed by belt
130 of in-feed conveyor 112, into engagement with puck unloading
conveyor 116. However, if the optical sensor in the vicinity of
station 152 detects a gap between adjacent pucks being delivered by
in-feed conveyor 112, then PLC 100, including transition apparatus
174 will be activated to terminate the continuation in supply of
pucks to the first group. If there is a gap between adjacent pucks
132, then pucks may not continue to be delivered in synchronization
with rods 145 of conveyor 116. Thus paddle 188 will rotate to the 6
o'clock position and member 187 will be extended, so as to block a
puck at or downstream from where the gap was detected, so that
there is no discontinuity in the positions of pucks being supplied
to puck unloading conveyor 116. It will be appreciated that the gap
in pucks should be detected at, or upstream of, where transition
apparatus 174 can intervene to interrupt the supply of pucks to
conveyor 116.
[0084] Transition apparatus 174 will thus have located a new lead
puck 132 and the next group of pucks will start to be accumulated
behind the next lead puck with paddle 188 rotated downwards and
member 187 extended. It will be appreciated that to try to ensure
that adjacent pucks with gaps therebetween do not try to engage
conveyor 116, the rearward movement along track 172 to the position
shown in FIG. 8d occur at a relatively high speed.
[0085] Optical sensors can also be provided both to ensure that
each puck 132 that is being carried by in-feed conveyor 112 is
filled with an item 150. If no item 150 is detected in a particular
puck 132, then a carton 117 may not be delivered by carton feeder
124 to a corresponding slot 121 on the carton conveyor 118.
[0086] PLC 100 may be configured to receive a signal from a sensor
identifying a puck 132 that is missing an item 150 and then may
then not send a carton through in the corresponding slot on carton
conveyor 118.
[0087] Alternatively, if a carton 117 is not properly delivered
into an appropriate slot on carton conveyor 118, this can also be
detected by a suitably placed optical sensor which can then cause
PLC 100 to have a corresponding pusher bar 300 not engage a
corresponding adjacent puck, so as not to push an item into a slot
121 without a properly aligned carton 117. This can be achieved by
operation of switch that diverts the cam follower of the
corresponding puck 132 down path B instead of path A (i.e. 312) on
item transfer apparatus 120.
[0088] In normal operation, while transition apparatus 174 is
providing for the transfer of pucks 132 to puck unloading conveyor
116, PLC 100 may also send a signal to rotary carton feeder 124 to
load an appropriate number of cartons from magazine 122 into
appropriate placed successive slots 121 on carton conveyor 118.
[0089] Meanwhile, the first group of pucks will be moving along the
path of conveyor 116 and will come into adjacent position to
cartons 117. Thereafter, as the pucks 132 and cartons 117 are
carried through station 151, pusher bars 300 with the assistance of
the confining members 340, will push items 150 out of receptacles
139 and into the aligned cartons 117.
[0090] Once unloaded of items 150, pucks 132 continue in their path
on conveyor 116 until they are discharged onto out-feed conveyor
262. At the same time, loaded cartons 117 may continue on carton
conveyor 118 for further processing, in a manner that is known. The
further processing of cartons 117 may include sealing of all flaps
on the cartons 117.
[0091] In other embodiments variations of the components described
above can be used. By way of example, instead of a transition
apparatus 174 which forms a group of pucks before making a
transition of the group onto puck unloading conveyor 116, pucks may
be moved to conveyor 116 on an individual basis upon arrival at
transition station 152. While the supply of pucks 132 to puck
unloading conveyor 116 may be intermittent, this can be
accommodated on the carton conveyor side in several ways. For
example, an optical sensor might be provided to provide a signal to
PLC 100 that a puck is being delivered to conveyor 116. In response
to receiving such a signal, PLC 100 may carton feeder 124 to feed a
carton 117 to carton conveyor 116 in an appropriate slot 121.
[0092] Other types of puck transition mechanisms could also be
employed. For example, a robot system combined with a vision system
could be configured to move pucks loaded with items from an in-feed
bucket conveyor onto a puck unloading conveyor
[0093] Of course, the above described embodiments, are intended to
be illustrative only and in no way limiting. The described
embodiments of carrying out the invention are susceptible to many
modifications of form, arrangement of parts, details and order of
operation. The invention, rather, is intended to encompass all such
modification within its scope, as defined by the claims.
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